Flush backing plate and related wall assemblies

ABSTRACT

An innovative flush mountable backing plate useful in the construction of sheet-metal wall assemblies is disclosed herein. The flush mountable backing plate is generally comprised of a flat piece of sheet-metal that defines a central web section having an end return flange positioned at one end and an end tab positioned at the other end, wherein the end return flange is perpendicular to the web section, while the end tab is coplanar with the web section; and a flexible bend section interposed between the end tab and the central web section, wherein the bend section defines a trough that runs perpendicular to the central web section, and wherein the trough is sized and configured to receive and does receive an inwardly directed return of one of the C-shaped studs.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Application No. 61/850,731 filed on Feb. 22, 2013, all of which application is incorporated herein by reference in its entirety for all purposes.

TECHNICAL FIELD

The present invention relates generally to building construction and, more specifically, to sheet metal backing plates or members useful for backing, bracing and/or supporting wall hung grab bars, hand rails, cabinets, shelves, and the like. The flush mountable backing plate of the present invention allows for a secure attachment and support for objects that place a load on a wall assembly and/or wall sheathing.

BACKGROUND OF THE INVENTION

Framing associated with building walls has historically been assembled from wooden members, including wooden studs and beams. In more recent years, however, the use of metal studs together with confronting channeled track members has gained wide acceptance, especially in new commercial buildings such as modern office buildings and hospitals. Generally speaking, metal studs and track members are stronger, more resistant to fire and economical than their wooden counterparts.

Metal framing assemblies are generally constructed from a plurality of metal framing members including metal studs, joists, trusses, and other metal posts and beams some of which are formed from sheet metal (and frequently fabricated to have the same general cross-sectional dimensions as standard wood members used for similar purposes). Sheet metal framing members are typically constructed by roll-forming 10 to 24 gauge galvanized sheet steel. Although many cross-sectional shapes are available, the primary shapes used in building construction are C-shaped studs and U-shaped tracks.

More specifically, metal studs are typically formed of galvanized sheet-metal bent to encompass a cross sectional area having nominal dimensions of two inches by four inches. Metal studs and related framing members are formed of sheet-metal bent into a generally U-shaped cross-section in which a relatively broad central base (web) is flanked by a pair of narrower sides (flanges) that are bent at right angles relative to the base (web). The central base (web) typically has a uniform nominal width of either three and ⅝ or four inches and is commonly referred to as the web. The sides of the U-shaped stud typically extend outwardly from the base a nominal distance of two inches and are commonly referred to as flanges. In order to enhance the structural rigidity of the flanges, the ends of flanges are typically bent over into a plane parallel to and spaced apart from the plane of the web. The turned over edges of the flanges define confronting marginal returns or lips that are typically ¼ to ½ inch in width.

During the framing of building walls, it is common practice to position wall studs at regularly spaced apart intervals relative to one another. For example, it is common practice to vertically position wall studs at 16 inches from center intervals. In addition, there is often a need for the studs to be transversely braced together, thereby providing enhanced structural rigidity to the frame-assembly. For example, studs over eight feet in length are generally transversely braced together to ensure adequate lateral stability of the wall structure (as well as to provide backing for attachment of wall sheathing). Exemplary devices that assist with the proper spacing and bracing of at least metal studs include those devices disclosed in U.S. Pat. No. 1,867,449 to Ecket et al. (discloses a metal fire block, bridging, and bracing element), U.S. Pat. No. 5,274,973 to Liang (discloses a notched stud spacer and mounting system), U.S. Pat. No. 6,021,618 to Elderson (discloses a notched stud spacer), U.S. Pat. No. 6,164,028 to Hughes (discloses a metallic bridging member), U.S. Pat. No. 6,983,569 to Rosenberg (discloses a notched stud spacer and bracing member together with a wall framing system), and U.S. Patent Application Publication No. 2007/023471 to Klein (discloses corrugated bracing strip). A problem associated with many of these devices is that they (i) lack flexibility to accommodate installation between adjacent studs, and/or (ii) they are not generally flush with the studs (resulting in “buildup”), and/or (iii) do not allow or accommodate the placement of in-wall plumbing and piping without additional cutting.

Although advances have been made over the years with respect to backing, spacing and bracing elements and systems used in wall assemblies, there is still a need in the art for new and improved framing elements that can be used as a backing, spacing, and/or cross-connecting bracing member in a wall assembly of a building. The present invention fulfills these needs and provides for further related advantages.

SUMMARY OF THE INVENTION

In brief, the present invention in one embodiment is directed to, useful in combination with a sheet-metal wall assembly, an innovative and flush mountable backing plate. The backing plate is removably positioned between first and second vertically oriented C-shaped sheet-metal studs, wherein the C-shaped sheet-metal studs have side flanges with inwardly directed returns, and wherein the side flanges also have outwardly facing side flange surfaces. In addition, the backing plate has an outwardly facing surface that is substantially flush with the side flange surfaces of the sheet-metal studs (hence, flush mountable).

In accordance with the present invention, the backing plate comprises: a flat piece of sheet-metal that defines a central elongated web section having an end return flange positioned at one end and an end tab positioned at the other end, wherein the end return flange is perpendicular to the web section, while the end tab is coplanar with the web section; and a flexible bend section interposed between the end tab and the central web section, wherein the bend section defines a trough that runs perpendicular to the central web section, and wherein the trough is sized and configured to receive and does receive an inwardly directed return of one of the C-shaped studs.

These and other aspects of the present invention will become more evident upon reference to the following detailed description and attached drawings. It is to be understood, however, that various changes, alterations, and substitutions may be made to the specific embodiments disclosed herein without departing from their essential spirit and scope.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings like reference numerals are used to designate like features throughout the several views of the drawings.

FIG. 1 is a front perspective partial view of a sheet-metal wall assembly having a flush backing plate positioned first and second vertically oriented C-shaped sheet-metal studs in accordance with an embodiment of the present invention.

FIG. 2 is a top view of the wall assembly having a flush backing plate shown in FIG. 3.

FIG. 3 is an elevated perspective view of a flush backing plate in accordance with an embodiment of the present invention, wherein the central bend section is in the form of a V-shaped profile.

FIG. 4 is an elevated perspective view of a flush backing plate in accordance with an alternative embodiment of the present invention, wherein the central bend section is in the form of a truncated V-shaped profile and a second end return flange connected perpendicular to the end tab (and parallel to the end return flange).

FIG. 5 is an elevated perspective view of a flush backing plate in accordance with an alternative embodiment of the present invention.

FIG. 6 is an elevated perspective view of a flush backing plate in accordance with an alternative embodiment of the present invention, wherein opposing lengthwise grooves (corrugation) are used to provide added strength and rigidity.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like references are used to designate like features and, more particularly, to FIGS. 1-3, the present invention in one embodiment is directed to, in combination with a sheet-metal wall assembly 10, an innovative and flush mountable backing plate 12. As shown in FIGS. 1 and 2, the backing plate 12 is positioned between first and second vertically oriented C-shaped sheet-metal studs 14, 16. As shown, the C-shaped sheet-metal studs 14, 16 each have side flanges 14′, 16′ with confronting and inwardly directed returns 14″, 16″. As further shown, the side flanges 14′, 16′ also have outwardly facing side flange surfaces that are substantially flush (coplanar) with the outwardly facing surface of the backing plate 12. In this configuration, all of the framing elements associated with the sheet-metal wall assembly 10 may be assembled together to be coplanar with respect to one another (meaning that localized wall “buildup” associated with uneven or protruding wall surfaces may be minimized and/or entirely avoided).

In accordance with the present invention and as best shown in FIG. 3, the backing plate 12 is made from a single flat piece of sheet-metal bent so as to define an elongated central web section 18 that has an end return flange 20 positioned at one end, and an end tab 22 positioned at the other end. As shown, the end return flange 20 is perpendicular to the web section 18, while the end tab 22 is coplanar with the web section 18. As further shown, a flexible bend section 24 is interposed between the end tab 22 and the central web section 18. In certain preferred embodiments (FIGS. 3-5), the central web section 18 further includes opposing central web section flanges 18′ positioned along the respective upper and lower edges of the central web section 18. In still other further embodiments (FIGS. 3 and 4), confronting reinforcing lips 18″ are positioned along the respective upper and lower edges of the web section flanges 18′. The opposing central web section flanges 18′ and confronting reinforcing lips 18″ provide added strength and rigidity to the backing plate 12. In still other further embodiments (FIG. 6), opposing lengthwise grooves (corrugation) 19 are used to provide added strength and rigidity.

As shown in FIGS. 1 and 2, the backing plate 12 is fastened to the first and second vertically oriented C-shaped sheet-metal studs 14, 16 by way of fasteners 17 (for example, screws), wherein at least one of the fasteners 17 penetrates through (i) the end tab 22 and the side flange 14′ of the first sheet-metal stud 14, and at least another of the fasteners 17 penetrates through (ii) the end return flange 214 and the web of the second sheet-metal stud 16.

As shown in FIGS. 2 and 3, the flexible bend section 24 defines a cross-wise trough 25 (sometimes referred to as a corrugation) that runs perpendicular to the central web section 18 (and parallel to the first and second vertically oriented C-shaped sheet-metal studs 14, 16). As shown, the trough 25 is sized and configured to receive and does receive the inwardly directed return 14″ of one of the C-shaped studs 14. In other words and as best shown in FIGS. 2 and 4 (alternative embodiment having a truncated V-shaped trough), the depth d of the trough is the same or greater than the height h of the inwardly directed return 14″ of one of the C-shaped studs 14. In connection with installation between adjacent studs, the flexible bend section 24 enables the end tab 22 to flex back and forth with respect to the central web section 18. Put differently, the flexible bend section 24 facilitates with the jimmying of the flush mountable backing plate 12 into position (between adjacent studs) This added flexibility greatly assists with assembling the sheet-metal wall assembly because the backing plate 12 can readily be shaped (meaning end tab 22 and web section 18 can be easily flexibly squished together) to fit between studs that are slightly off center. In certain preferred embodiments (FIG. 4), the flexible bend section 24 is a truncated V-shaped profile (meaning a truncated V-shaped cross-sectional profile). In other embodiments, the flexible bend section 24 is U-shaped (not shown). In still further embodiments (FIG. 4), a second end return flange 23 is connected perpendicular to the end tab 22 (and parallel to the end return flange 20 connected to the other end of the elongated central web section 18).

While the present invention has been described in the context of the embodiments illustrated and described herein, the invention may be embodied in other specific ways or in other specific forms without departing from its spirit or essential characteristics. Therefore, the described embodiments are to be considered in all respects as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

What is claimed is:
 1. In combination with a sheet-metal wall assembly, a flush mounted backing plate positioned between first and second vertically oriented C-shaped sheet-metal studs, wherein the C-shaped sheet-metal studs have side flanges with inwardly directed returns, and wherein the side flanges also have outwardly facing side flange surfaces, and wherein the backing plate has an outwardly facing surface that is substantially flush with the side flange surfaces of the sheet-metal studs, the backing plate comprising: a flat piece of sheet-metal that defines a central web section having an end return flange positioned at one end and an end tab positioned at the other end, wherein the end return flange is perpendicular to the web section, while the end tab is coplanar with the web section; and a flexible bend section interposed between the end tab and the central web section, wherein the bend section defines a trough that runs perpendicular to the central web section, and wherein the trough is sized and configured to receive and receives an inwardly directed return of one of the C-shaped studs.
 2. The sheet-metal wall assembly of claim 1, wherein the backing plate is fastened to the first and second vertically oriented C-shaped sheet-metal studs by way of fasteners, wherein at least one of the fasteners penetrates through (i) the end tab and the side flange of the first sheet-metal stud, and at least another of the fasteners penetrates through (ii) the end return flange and a web of the second sheet-metal stud.
 3. The sheet-metal wall assembly of claim 1, wherein the flexible bend section enables the end tab to flex back and forth with respect to the central web section.
 4. The sheet-metal wall assembly of claim 3, wherein the flexible bend section is a truncated V-shape.
 5. The sheet-metal wall assembly of claim 4 further comprising central web section flanges positioned along the respective upper and lower edges of the central web section.
 6. The sheet-metal wall assembly of claim 5 further comprising reinforcing lips positioned along the respective upper and lower edges of the web section flanges.
 7. The sheet-metal wall assembly of claim 5 further comprising a second end return flange connected perpendicular to the end tab and parallel to the end return flange. 